Detailed Subsystem Level Design Review

Transcription

1 Detailed Subsystem Level Design Review Reciprocating Friction Tester Thursday November 20th, 2014

2 : Armature Subsystem Eric Kutil (ME): Project Manager Specialty: Solid Modeling and Machining Chris Karamanos (IE): Data Manager Specialty: Process Improvement Reba Conway (ME): Note Taker Specialty: Solid Modeling and GD&T Kolby Irving (EE): Gatekeeper Specialty: Lab-View Software Emeka Okoye (EE): Supply Manager Specialty: Electronic Hardware Gary Werth: Project Guide

3 Review

4 Engineering Requirements

5 Analysis: Functional Decomposition

6 Armature Functions

7 Preliminary Drawing of Design

8 Assembly System: Arm

9 Arm Assembly Rear Block Subsystem Normal Force Subsystem Strain Gauge Rod Subsystem Counterbalance Subsystem Front Block Subsystem

10 Subsystem: Rear Block Description: Rear Block that supports arm Machined out of 6061 aluminum Description: Clamps strain gauge rod to front and rear block Machined out of 6061 aluminum

11 Test Plan Example

12 Subsystem: Strain Gauge Rod (Mechanical) Rod Strain Gauge

13 Deflection Analysis Faculty SME Sign Off: Dr. Kempski

14 Fatigue Life Analysis Faculty SME Sign Off: Dr. Kempski

15 Vibration Analysis Faculty SME Sign Off: Dr. Ghoneim

16 Subsystem: Strain Gauge Rod (Electrical)

17 Sensor Selection Key factors to consider: Gauge factor Sensitivity Size Must mount to 6x10 mm surface Choice: Vishay WK PC350 Fully encapsulated K-alloy gauge with high-endurance leadwires 9/30/14

18 Sensor Set-up Full bridge: Four active strain gage elements Compensates completely for temperature variations Compensates for partial resistance Highest degree of accuracy No completion resistors needed Confirmed best set-up by Dr. John Wellin 9/30/14

19 Sensor Wiring Each one of the corners represents a pad on the bondable terminal strip Four pads are required on the specimen Pull out three wires from each pad One wire will go to instrumentation. Other two will go to two different strain gauges 9/30/14

20 Strain-Voltage-Force Analysis Signed off by Dr James Moon(EE)

21 Sensor Tolerance Analysis

22 Sensor Interface Diagram

23 Mounting the Sensor

24 Example Sensor Test Plan

25 Subsystem: Front Block Description: Front block which the holds the Pin and supports normal force weights Machined out of 6061 aluminum Description: Pin that holds the ball specimen Supplied by our customer Description: Clamps strain gauge rod to front and rear block Machined out of 6061 aluminum

26 Z-Axis Adjustment 33.8mm of safe ZAxis adjustment with 4 set screws engaged

27 Pin Holder Test Plans: Secure

28 Subsystem: Counterbalance

29 Counterbalance Analysis Faculty SME Sign Off: Dr. Leipold

30 Subsystem: Normal Force 20N 15N 10N 0.5N 1N 2N 5N

31 Normal Force Test Plan

32 Mass and COG of Custom Components Analysis Faculty SME Sign Off: Dr. Leipold

33 Arm BOM

34 Arm BOM Main Assemblies

35 Assembly System: Base

36 Base Assembly Mounting Subsystem X-Axis Subsystem

37 Base BOM

38 Mount Assembly Part Drawings for parts we are machining are found later in powerpoint

39 X-Axis Assembly Part Drawings for parts we are machining are found later in powerpoint

40 Mount Test Plan

41 X-Axis Test Plan

42 X-Axis Base Test Plan

43 Complete Armature

44 Complete Armature Assembly

45 Y-Axis and X-Axis Adjustment Y-Axis: Total of 49mm of adjustment Procedure: 1. Loosen set screw on arm 2. Adjust arm to desired position 3. Torque set screw to 15Nm X-Axis: Total of 37.7mm of adjustment Procedure: 1. Loosen locking handle 2. Adjust mounting base with crank wheel 3. Tighten locking handle

46 Pin Interchangeability Pin Changing Procedure 1. Slide mounting assembly all the way back 2. Slide arm full left 3. Tilt arm back 4. Loosen 4 set screws 5. Remove pin and replace

47 Assembly Process

48 Assembly Process

49 Assembly Process

50 Assembly Process

51 Action Items Create process sheets for fabrication of parts Chris Verify each process is correct Everyone Determine who will be assembling Reba, Eric Purchase Requisition Documents Emeka Get Date for Rob Kraynik to Install Strain Gauges Kolby, Emeka Begin fabricating force weights and aluminum blocks Eric, Chris

52 Rest of MSD1

53 Risks FML

54 Problems Encountered Having to wait until design is finalized Working on sub-versioned files at the same time Professor scheduling conflicts to obtain SME approvals Lessons Learned More peer reviews together as a team Seek assistance from teammates when swamped with work Seek assistance from guide as necessary Schedule more time for senior design work Account for being busy like doing interviews and other work in classes

55 Moving Forward: MSD2

56 Moving Forward: MSD2

57 Questions?

58 Extraneous Information

59 Mounting.Asm Part Drawings

60 Arm.Asm Part Drawings

61 Arm.Asm Part Drawings